Preform Fabrication System

ABSTRACT

An embodiment of the present disclosure provides a method and apparatus for managing a part. The method comprises identifying, by a computer system, parameters for the part. Further, the method comprises identifying, by the computer system, a number of additional parameters used in manufacturing the part from a preform. Yet further, the method comprises automatically generating, by the computer system, a preform design for the preform using the parameters for the part and the number of additional parameters, wherein the preform design enables manufacturing the preform using an additive manufacturing system in a manufacturing environment.

BACKGROUND INFORMATION

1. Field

The present disclosure relates generally to improved manufacturing and,in particular, to a method and apparatus for manufacturing a preform fora part. Still more particularly, the present disclosure relates to amethod and apparatus for generating a design for manufacturing a preformfor a part.

2. Background

Additive manufacturing is a process in which a three-dimensional objectis formed. In additive manufacturing, successive layers of material maybe formed to create an object. Objects created using additivemanufacturing may be of almost any shape.

Additive manufacturing may be used for a number of different purposes.For example, additive manufacturing is used to manufacture parts orprototypes for parts that are used in objects such as aircraft,automobiles, ships, trains, machinery, medical devices, and othersuitable objects.

Additive manufacturing is used to manufacture parts using materials.These materials may be, for example, metals, polymers, ceramicmaterials, metal alloy, titanium, thermoplastics, and other suitabletypes of materials.

Additive manufacturing may be performed using a number of differenttechnologies. For example, additive manufacturing may be performed bymelting or softening a material to produce layers. This type ofmanufacturing may include selective laser melting, direct metal lasersintering, selective laser sintering, fused deposition modeling, orother suitable techniques.

In another example, additive manufacturing may be performed using metalwire processes. For example, an electron-beam wire feed system is anadditive manufacturing system that feeds wire through a nozzle. The wirefed through the nozzle is melted by an electron-beam. This type ofmanufacturing is referred to as electron-beam additive manufacturing(EBAM). In another example, the wire may be melted using a laser beam.This type of additive manufacturing uses electron beams or lasers, whichare often used for fabricating metal parts.

The melting of the wire forms oversized layers that become a preform forthe part. A preform is an object that is further processed to form thepart. These oversized layers may then be machined, or otherwiseprocessed, to form the final shape for the part.

A preform design for the preform manufactured using the wire basedadditive manufacturing system is based on the part design for the part.These designs are electronic files, such as computer-aided design (CAD)files. For example, a designer modifies the part design to create thepreform design. Thereafter, the designer sends the preform design tomanufacturers for review.

A first manufacturer reviews the preform design and provides feedbackwith respect to the feasibility and cost for manufacturing a preform. Asecond manufacturer may review the preform design to identify thefeasibility of machining the preform to form the part.

The first manufacturer may consider rules that are present with respectto laying down the wire to form the preform using an additivemanufacturing system. For example, locations for the substrate, thedirection that the wire is laid down, how a wire can be laid on a priorwire, and other rules are present.

The second manufacturer may consider other rules for machining a preformto form the part. Depending on the type of tools used for machining thepreform to form the features in the part, different amounts of excessmaterial may be needed to form different types of parts. For example, apart with holes, groups, protrusions, or other features may requiredifferent amounts of excess material in the preform to properly formthose features when machining the preform.

Additionally, the review also may include cost estimates formanufacturing the preform, manufacturing the part from the preform, orsome combination thereof. The cost to manufacture the part may be basedon how much material is used for the preform, the cost to create aprogram for the additive manufacturing system, the cost to create aprogram for the machining system for machining the preform to form thepart, and other factors.

The manufacturers provide feedback to the designer after reviewing thepreform design. The designer may make modifications to the preformdesign based on the feedback from the manufacturer. For example, thepreform design may not be usable for manufacturing a preform. As anotherexample, the manufacturer may return a cost estimate that may be greaterthan desired for manufacturing the part using the preform manufacturedfrom the preform design. As a result, the preform design may be changedto make the preform more feasible for machining to form the part. Asanother example, the preform design may be changed to reduce the amountof material resulting in the cost identified for manufacturing the partbeing reduced. This type of design modification and review may occurseveral times to finalize the preform design.

The steps involved in creating the preform design, reviewing the preformdesign, returning feedback, and modifying the preform design as neededmay be performed several times. Currently, the steps may take more timethan desired in creating the preform design for the preform tomanufacture a part. Additionally, the creation and modification of thepreform design is subjective based on people creating the preform designand reviewing the preform design.

Therefore, it would be desirable to have a method and apparatus thattake into account at least some of the issues discussed above, as wellas other possible issues. For example, it would be desirable to have amethod and apparatus that overcome a technical problem with the time andeffort needed to create a preform design.

SUMMARY

An embodiment of the present disclosure provides an apparatus. Theapparatus comprises a part manager. The part manager identifiesparameters for a part. Further, the part manager identifies a number ofadditional parameters used in manufacturing the part from a preform. Yetfurther, the part manager automatically generates a preform design forthe preform using the parameters for the part and the number ofadditional parameters, wherein the preform design enables manufacturingthe preform using an additive manufacturing system.

Another embodiment of the present disclosure provides a method formanaging a part. The method comprises identifying, by a computer system,parameters for the part. Further, the method comprises identifying, bythe computer system, a number of additional parameters used inmanufacturing the part from a preform. Yet further, the method comprisesautomatically generating, by the computer system, a preform design forthe preform using the parameters for the part and the number ofadditional parameters, wherein the preform design enables manufacturingthe preform using an additive manufacturing system in a manufacturingenvironment.

Yet another embodiment of the present disclosure provides a preformmanagement system. The preform management system comprises a partmanager. The part manager identifies parameters for a part, andidentifies a number of additional parameters for manufacturing the partfrom a preform. Further, the part manager generates a preform design forthe preform. Yet further, the part manager displays the preform designon a display system. Still further, the part manager outputs feasibilityinformation about the preform, wherein the preform design enablesmanufacturing the preform using an additive manufacturing system.

The features and functions can be achieved independently in variousembodiments of the present disclosure or may be combined in yet otherembodiments in which further details can be seen with reference to thefollowing description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the illustrativeembodiments are set forth in the appended claims. The illustrativeembodiments, however, as well as a preferred mode of use, furtherobjectives, and features thereof, will best be understood by referenceto the following detailed description of an illustrative embodiment ofthe present disclosure when read in conjunction with the accompanyingdrawings, wherein:

FIG. 1 is an illustration of a block diagram of a part environment inaccordance with an illustrative embodiment;

FIG. 2 is an illustration of a block diagram showing data flow inmanaging a part in accordance with an illustrative embodiment;

FIG. 3 is an illustration of a graphical user interface for identifyingadditional parameters in accordance with an illustrative embodiment;

FIG. 4 is an illustration of a graphical user interface displaying apart design in accordance with an illustrative embodiment;

FIG. 5 is an illustration of the identification of a substrate inaccordance with an illustrative embodiment;

FIG. 6 is an illustration of cross-sections in accordance with anillustrative embodiment;

FIG. 7 is an illustration of cross-sections projected onto a substratein accordance with an illustrative embodiment;

FIG. 8 is an illustration of shaded cross-sections in accordance with anillustrative embodiment;

FIG. 9 is an illustration of layers for a preform design in accordancewith an illustrative embodiment;

FIG. 10 is an illustration of layers for a preform on a part design inaccordance with an illustrative embodiment;

FIG. 11 is an illustration of a three-dimensional geometry in accordancewith an illustrative embodiment;

FIG. 12 is an illustration of a preform design in accordance with anillustrative embodiment;

FIG. 13 is an illustration of output for evaluating a preform design inaccordance with an illustrative embodiment;

FIG. 14 is an illustration of a flowchart of a process for managing apart in accordance with an illustrative embodiment;

FIG. 15 is an illustration of a flowchart of a process for managing themanufacturing of a part from a preform in accordance with anillustrative embodiment;

FIG. 16 is an illustration of a flowchart of a process for creating apreform design in accordance with an illustrative embodiment;

FIG. 17 is an illustration of a block diagram of a data processingsystem in accordance with an illustrative embodiment;

FIG. 18 is an illustration of a block diagram of an aircraftmanufacturing and service method in accordance with an illustrativeembodiment;

FIG. 19 is an illustration of a block diagram of an aircraft in which anillustrative embodiment may be implemented; and

FIG. 20 is an illustration of a block diagram of a product managementsystem in accordance with an illustrative embodiment.

DETAILED DESCRIPTION

The illustrative embodiments recognize and take into account one or moredifferent considerations. The illustrative embodiments recognize andtake into account that the current steps performed by the designer andmanufacturer to create a preform design to manufacture a preform andthen process the preform to form a part may not be as accurate asdesired.

The illustrative embodiments recognize and take into account that thistechnical issue may arise from the current steps used to create preformdesigns. The illustrative embodiments recognize and take into accountthat designers often do not consider one or more of the thickness oflayers formed by a particular type of additive manufacturing system, thedirections for laying wires, the direction in which layers are built onthe substrate, substrate locations, excess material, and otherconsiderations that affect the amount of material needed to form apreform when creating a preform design from a part design.

The illustrative embodiments recognize and take into account thatconsidering all of the different considerations may take more time thandesired and also cost more than desired. If fewer factors are taken intoaccount, then the feasibility and cost estimates for manufacturing apreform and then processing the preform to form a part may not be asaccurate as desired.

Thus, the illustrative embodiments provide a method and apparatus formanaging the part. In one illustrative example, a computer systemidentifies parameters for a part and identifies a number of additionalparameters used in manufacturing the part from a preform. The computersystem also automatically generates a preform design for the preformusing the parameters for the part and the number of additionalparameters, wherein the preform design enables manufacturing the preformusing an additive manufacturing system in a manufacturing environment.

With reference now to the figures and, in particular, with reference toFIG. 1, an illustration of a block diagram of a part environment isdepicted in accordance with an illustrative embodiment. In thisillustrative example, part environment 100 includes part manufacturingsystem 102 that operates to manufacture parts 104. Parts 104 may be usedto manufacture object 106 or perform maintenance on object 106.

Object 106 may take a number of different forms. For example, object 106may be selected from one of a mobile platform, a stationary platform, aland-based structure, an aquatic-based structure, or a space-basedstructure. More specifically, object 106 may be a surface ship, a tank,a personnel carrier, a train, a spacecraft, a space station, asatellite, a submarine, an automobile, a power plant, a bridge, a dam, ahouse, a manufacturing facility, a building, or other suitable objects.Object 106 may also be selected from one of an engine, an enginehousing, a flap, a horizontal stabilizer, a strut, a generator, acomputer, a speaker, a biomedical device, a communications device, orsome other suitable object.

In this illustrative example, part 108 in parts 104 may be manufacturedusing preform 110. As depicted, preform 110 is manufactured by additivemanufacturing system 112. Preform 110 may be processed by machiningsystem 114 to form part 108.

Additive manufacturing system 112 includes one or more pieces ofequipment that create preform 110 by forming successive layers of one ormore materials. As depicted, additive manufacturing system 112 mayinclude at least one of an electron beam additive manufacturing system,a powder based electron beam additive manufacturing system, a wire basedelectron beam additive manufacturing system, a laser additivemanufacturing system, a selective heat sintering system, a lasersintering system, a fusion deposition modeling system, or some othersuitable system that performs additive manufacturing.

As used herein, the phrase “at least one of”, when used with a list ofitems, means different combinations of one or more of the listed itemsmay be used, and only one of each item in the list may be needed. Inother words, “at least one of” means any combination of items and numberof items may be used from the list, but not all of the items in the listare required. The item may be a particular object, thing, or a category.

For example, without limitation, “at least one of item A, item B, oritem C” may include item A, item A and item B, or item B. This examplealso may include item A, item B, and item C or item B and item C. Ofcourse, any combination of these items may be present. In someillustrative examples, “at least one of” may be, for example, withoutlimitation, two of item A; one of item B; and ten of item C; four ofitem B and seven of item C; or other suitable combinations.

In the illustrative example, machining system 114 includes one or morepieces of equipment that remove materials from preform 110 to form part108. As depicted, machining system 114 may be selected from at least oneof a lathe, a milling machine, an electrical discharge machining system,a water jet cutting system, a laser cutting system, or some othersuitable piece of equipment.

In this illustrative example, part manager 116 manages parts 104,including part 108. Part manager 116 may be implemented in software,hardware, firmware, or a combination thereof. When software is used, theoperations performed by part manager 116 may be implemented in programcode configured to run on hardware, such as a processor unit. Whenfirmware is used, the operations performed by part manager 116 may beimplemented in program code and data and stored in persistent memory torun on a processor unit. When hardware is employed, the hardware mayinclude circuits that operate to perform the operations in part manager116.

In the illustrative examples, the hardware may take a form selected fromat least one of a circuit system, an integrated circuit, an applicationspecific integrated circuit (ASIC), a programmable logic device, or someother suitable type of hardware configured to perform a number ofoperations. With a programmable logic device, the device may beconfigured to perform the number of operations. The device may bereconfigured at a later time or may be permanently configured to performthe number of operations. Programmable logic devices include, forexample, a programmable logic array, a programmable array logic, a fieldprogrammable logic array, a field programmable gate array, and othersuitable hardware devices. Additionally, the processes may beimplemented in organic components integrated with inorganic componentsand may be comprised entirely of organic components, excluding a humanbeing. For example, the processes may be implemented as circuits inorganic semiconductors.

Computer system 118 is a physical hardware system and includes one ormore data processing systems. When more than one data processing systemis present, those data processing systems are in communication with eachother using a communications medium. The communications medium may be anetwork. The data processing systems may be selected from at least oneof a computer, a server computer, a tablet, or some other suitable dataprocessing system.

As depicted, part manager 116 identifies parameters 120 for part 108.Parameters 120 may be obtained from part design 122. Part design 122 maybe a computer aided design (CAD) model, a two-dimensional model, or athree-dimensional model of part 108. Parameters 120 in part design 122are information about part 108. For example, parameters 120 includedimensions for part 108 and may also include at least one of materials,processes, inspection information, tolerances, manufacturing excesses,finishing operations, grain direction, machining techniques, or othersuitable parameters about part 108.

For example, parameters 120 may include parameters relating to machiningtechniques, such as waterjet, laser, thermal, or other suitablemachining techniques. As another example, parameters 120 includeparameters that take into account considerations for the preform thatare needed to perform finishing operations, such as paint, primeanodize, or other suitable types of finishing operations.

Part manager 116 also identifies a number of additional parameters 124used in manufacturing part 108 from preform 110. As used herein, “anumber of”, when used with reference to items, means one or more items.For example, a number of additional parameters 124 is one or more ofadditional parameters 124.

In this illustrative example, the number of additional parameters 124 isinformation used in creating preform design 126 for preform 110. Asdepicted, the number of additional parameters 124 is selected from atleast one of a build direction, a substrate location, a substratethickness, an additive material offset, a plate excess, a substrateexcess, a material density, an additive layer thickness, a platethickness, or some other suitable type of parameter.

As depicted, the number of additional parameters 124 selected and thevalues for the number of additional parameters 124 may be usingconsiderations selected from at least one of considerations for formingpreform 110 from preform design 126 based on the particular type ofadditive manufacturing system, considerations for processing preform 110by machining system 114 to form part 108, or other suitable types offactors that may be used in creating preform design 126. Otherconsiderations may include, for example, selections of material, costs,the manner in which material lays up to form layers, excess materialneeded for machining, excess material needed to handle the preform,environmental concerns, and other suitable considerations.

In this illustrative example, part manager 116 automatically generatespreform design 126 for preform 110 using parameters 120 for part 108 andthe number of additional parameters 124. As depicted, automaticallygenerating preform design 126 means that part manager 116 generatespreform design 126 without needing to receive user input to createpreform design 126. Preform design 126 enables manufacturing preform 110using additive manufacturing system 112.

Further, part manager 116 may manufacture preform 110 using preformdesign 126. In other words, part manager 116 may control the operationof additive manufacturing system 112 to manufacture preform 110 usingpreform design 126.

For example, part manager 116 may generate instructions for additivemanufacturing system 112 using preform design 126 and the number ofadditional parameters 124. Preform 110 is manufactured using theinstructions and additive manufacturing system 112. As depicted, theinstructions are used by additive manufacturing system 112 to formpreform 110 for part 108. The instructions are selected from at leastone of commands, program code, source code, machine code, or some othersuitable types of instructions that may be used to control additivemanufacturing system 112.

After preform 110 has been manufactured using additive manufacturingsystem 112, part manager 116 may process preform 110 to form part 108.For example, part manager 116 may machine preform 110 to form part 108by controlling machining system 114.

With reference now to FIG. 2, an illustration of a block diagram showingdata flow in managing a part is depicted in accordance with anillustrative embodiment. In the illustrative examples, the samereference numeral may be used in more than one figure. This reuse of areference numeral in different figures represents the same element inthe different figures.

In this illustrative example, computer system 118 has display system 200and input system 202. Display system 200 is a physical hardware systemand includes one or more display devices on which graphical userinterface 204 may be displayed. The display devices may include at leastone of a light emitting diode (LED) display, a liquid crystal display(LCD), an organic light emitting diode (OLED) display, or some othersuitable device on which graphical user interface 204 can be displayed.

Operator 206 is a person that may interact with part manager 116 viagraphical user interface 204. This interaction may be through user input208 to graphical user interface 204 generated by input system 202 incomputer system 118. Input system 202 is a physical hardware system andmay be selected from at least one of a mouse, a keyboard, a trackball, atouchscreen, a stylus, a motion sensing input device, a cyberglove, orsome other suitable type of input device.

As depicted, part manager 116 in computer system 118 receives aselection of part design 122 for part 108 in user input 208. Theselection in user input 208 may be a selection of a computer aideddesign (CAD) file or some other file in which part design 122 islocated.

Part manager 116 uses the selection in user input 208 to identify partdesign 122. With the identification of part design 122, part manager 116identifies parameters 120 for part 108 from part design 122.

Further, part manager 116 also may receive the number of additionalparameters 124 as part of selection 210 in user input 208. The number ofadditional parameters 124 may be received directly in user input 208. Inother illustrative examples, the number of additional parameters 124 maybe received as the identification of a file in which the number ofadditional parameters 124 is located. In still other illustrativeexamples, the number of additional parameters 124 may be located in adefault configuration file that is identified by part manager 116without requiring the user input 208.

With the identification of parameters 120 for part 108 and theidentification of additional parameters 124, part manager 116automatically generates preform design 126. Generation of preform design126 occurs automatically such that additional user input from operator206 or some other operator is unnecessary to generate preform design126. For example, preform design 126 is not made by user input 208 fromoperator 206 modifying part design 122 displayed in graphical userinterface 204 on display system 200.

In this illustrative example, part manager 116 may repeat identifyingthe number of additional parameters 124 and automatically generatingpreform design 126 until preform design 126 meets a number of desiredgoals. In performing these operations, part manager 116 changes thenumber of additional parameters 124.

For example, values for the number of additional parameters 124 may bechanged by entering values in user input 208. By changing the values,the amount of material, the time needed, or the difficulty inmanufacturing preform 110 may be reduced.

Further, the particular additional parameters in the number ofadditional parameters 124 used may be changed. In other words, one ormore different parameters may be used for the number of additionalparameters 124.

Part manager 116 also may generate output 212. In this illustrativeexample, output 212 is information related to preform design 126. Inparticular, output 212 may be generated using preform design 126.

For example, output 212 may include evaluation information 214 that isused to determine whether to repeat identifying the number of additionalparameters 124 and automatically generating preform design 126 withparameters 120 and changes to the number of additional parameters 124.Evaluation information 214 is generated using preform design 126. Inthis manner, iterations of preform design 126 may be generated untilpreform design 126 meets desired goals.

For example, evaluation information 214 identified by part manager 116may include at least one of a weight for preform 110 in FIG. 1, a costestimate for preform 110, a manufacturing time for preform 110, amachining time to form part 108 in FIG. 1 from preform 110, a type ofpart, or other suitable information that may be used to evaluate thefeasibility of manufacturing preform 110 using preform design 126,manufacturing part 108 from preform 110, or some combination thereof.

The change to preform design 126 also may be made in response toanalyzing evaluation information 214. In this illustrative example, theanalysis of evaluation information 214 may be made by at least one ofpart manager 116, operator 206, or some other entity.

For example, if evaluation information 214 indicates that the costestimate for manufacturing preform 110 from preform design 126 isgreater than desired, the number of additional parameters 124 may bechanged in an effort to reduce the cost estimate. Changes to the numberof additional parameters 124 results in a change in preform design 126that may more closely meet a number of goals for preform design 126.

As another illustrative example, output 212 also may includevisualization 216. Visualization 216 is a visualization of preformdesign 126 that is displayed in graphical user interface 204 on displaysystem 200. For example, preform design 126 may be displayed ingraphical user interface 204 by a computer-aided design applicationrunning on computer system 118.

Visualization 216 may be viewed by operator 206 to determine whether tomake changes to the number of additional parameters 124. If changes aremade in the values or which parameters are used for the number ofadditional parameters 124, preform design 126 may be automaticallygenerated using these changes.

In this manner, iterations of preform design 126 also may be madethrough visualization 216. These changes to the number of additionalparameters 124 may result in a change to preform design 126 made by partmanager 116.

Further, output 212 may be used for other purposes in managing part 108.For example, evaluation information 214 in output 212 may be used tomanage the manufacturing of at least one of preform 110 or part 108 inFIG. 1. As another example, evaluation information 214 in output 212 maybe used to determine whether preform 110 should be manufactured usingadditive manufacturing system 112 in FIG. 1. As yet another example,output 212 may be used to select a particular type of system in additivemanufacturing system 112 to manufacture preform 110.

In one illustrative example, one or more technical solutions are presentthat overcome a technical problem with the time and effort needed tocreate a preform design. As a result, one or more technical solutionsmay provide a technical effect in which preform design 126 is generatedautomatically without requiring user input 208.

Further, the generation of preform design 126 is an improvement overcurrently used techniques in which human operators create preformdesigns using computer-aided design applications. For example, partmanager 116 automatically generates part design 122 without needing userinput 208 from operator 206.

As described above, one or more the illustrative examples provide amethod and apparatus that overcome a technical problem with the time andeffort needed to create a preform design. In the illustrative example,part manager 116 automatically generates preform design 126 fromparameters 120 for part design 122 and a number of additional parameters124 used in manufacturing preform 110.

In the illustrative example, part manager 116 allows for changes topreform design 126 to be made more quickly as compared to currently usedtechniques. Further, part manager 116 generates preform design 126without needing operator 206 to modify part design 122 displayed ingraphical user interface 204 to form preform design 126. By eliminatingthe need for this operation, preform design 126 may be generated morequickly and accurately as compared to currently used techniques.

Further, with the use of additional parameters 124 in conjunction withparameters 120 from part design 122, preform design 126 may be generatedby part manager 116 in a manner that takes into account differentconsiderations desirable for processing preform 110 manufactured byadditive manufacturing system 112 in FIG. 1 to create part 108.

The illustration of part environment 100 and the different componentsfor part environment 100 in FIG. 1 and FIG. 2 are not meant to implyphysical or architectural limitations to the manner in which anillustrative embodiment may be implemented. Other components in additionto or in place of the ones illustrated may be used. Some components maybe unnecessary. Also, the blocks are presented to illustrate somefunctional components. One or more of these blocks may be combined,divided, or combined and divided into different blocks when implementedin an illustrative embodiment.

For example, part environment 100 may omit machining system 114 inimplementations in which part manufacturing system 102 manufacturespreforms and not parts. As another example, part environment 100excludes additive manufacturing system 112 and machining system 114. Inthis type of implementation, part manager 116 in part environment 100may evaluate the feasibility of manufacturing preforms for parts 104from preform designs.

With reference now to FIGS. 3-13, illustrations of a process forgenerating a preform design are depicted in accordance with illustrativeembodiments. With reference first to FIG. 3, a graphical user interfacefor identifying additional parameters is depicted in accordance with anillustrative embodiment. In this figure, graphical user interface 300displays window 302. Graphical user interface 300 is an example of oneimplementation for graphical user interface 204 that is displayed bypart manager 116 as shown in block form in FIG. 2.

In this illustrative example, window 302 includes additional parameters304. Additional parameters 304 may have values set through user input tographical user interface 300. As depicted, additional parameters 304 areparameters for manufacturing a part from a preform.

In this illustrative example, additional parameters 304 include additivematerial offset 306, plate excess 308, substrate excess 310, materialdensity 312, additive layer thickness 314, and plate thickness 316.These additional parameters in additional parameters 304 are selectedfor an electron beam additive manufacturing system that uses wire toform layers for a preform. For example, some of additional parameters304 take into account the manner in which the substrate may be laid upto form a preform that may then be machined to form the part.

As depicted, additive material offset 306 is the amount of excessmaterial that is needed for machining a preform to form a part. Plateexcess 308 is the amount of additional material needed in the plate fortooling features. A plate is a type of substrate on which the layers maybe formed through additive manufacturing.

The plate may have different shapes. For example, the plate may besquare, rectangular, circular, trapezoidal, or have some other shape.The plate may be planar, curved, or have some other shape. These toolingfeatures may include tooling holes, a flange used to hold a plate inplace, and other types of features that are used in manufacturing thepreform.

In this illustrative example, substrate excess 310 is the amount ofmaterial in the substrate that is needed for features that may be partof the preform. For example, the substrate may be selected to have athickness for a base for the preform. Substrate excess 310 also mayinclude excess material that may be machined to form features such asholes, groups, or other features for the preform.

Material density 312 is the density of the wire that is heated to formthe layers for the preform. As depicted, additive layer thickness 314 isthe thickness of each layer that is formed during the additivemanufacturing process to manufacture the preform. In this illustrativeexample, plate thickness 316 is the amount of excess in the substratethat is needed for a desired plate thickness for the preform.

With reference next to FIG. 4, an illustration of a graphical userinterface displaying a part design is depicted in accordance with anillustrative embodiment. In this figure, part design 400 is displayed ingraphical user interface 300. The display of part design 400 allows fora selection of facet 402 for the substrate location and build directionof the preform.

In this illustrative example, the selection may be made by user inputselecting facet 402. In another illustrative example, facet 402 may beselected by part manager 116 in FIG. 1 performing an analysis on partdesign 400. Analysis may select the best facet in part design 400 formanufacturing a preform for the part.

The best facet may be varied, depending on the desired goal. Forexample, if the goal is to avoid forming layers that extend from twodirections of the substrate, then the facet may be selected to avoid apreform design with features extending from both sides of the substrate.

In this illustrative example, a facet is a face on part design 400. Inthis illustrative example, the build direction is the direction of arrow404 perpendicular to facet 402 on part design 400. The build directionis the direction that the layers are formed or built up on thesubstrate.

With reference now to FIG. 5, an illustration of the identification of asubstrate is depicted in accordance with an illustrative embodiment. Inthis illustrative example, substrate 500 is identified as displayed ingraphical user interface 300. Substrate 500 is the substrate on whichlayers are formed by an electron beam additive manufacturing system thatuses a wire.

In this illustrative example, substrate 500 is identified usingadditional parameters 304 in FIG. 3. The identification of substrate 500includes a location, as well as dimensions for substrate 500.

Further, the selected facet is used to identify a substrate. Parametersthat may be used to identify the substrate include, for example,additive material offset 306 and plate thickness 316 in FIG. 3.

Turning next to FIG. 6, an illustration of cross-sections is depicted inaccordance with an illustrative embodiment. In this illustrativeexample, part manager 116 in FIG. 1 identifies cross-sections 600 inpart design 400. As depicted, cross-sections 600 are parallel tosubstrate 500.

The thicknesses of the cross-sections 600 are identified usingadditional parameters 304 in FIG. 3. For example, cross-sections 600 areidentified using additive layer thickness 314 in additional parameters304 in FIG. 3.

In FIG. 7, an illustration of cross-sections projected onto a substrateis depicted in accordance with an illustrative embodiment. As depicted,two-dimensional geometries 700 from cross-sections 600 in part design400 in FIG. 6 are created by part manager 116 in FIG. 1 as shown ingraphical user interface 300. In this example, two-dimensionalgeometries 700 are two-dimensional cross-sections. In this illustrativeexample, two-dimensional geometries 700 are created by part manager 116from a projection of cross-sections 600 onto substrate 500.

Turning next to FIG. 8, an illustration of shaded cross-sections isdepicted in accordance with an illustrative embodiment. In this figure,shaded cross-sections 800 are shown in graphical user interface 300.Shaded cross-sections 800 are created by part manager 116 in FIG. 1 fromBoolean unions of two-dimensional geometries 700 in FIG. 7.

In the illustrative example, the union “C” of two regions, region “A”and region “B”, is a new region where any point that was in eitherregion “A” or region “B” or both region “A” and region “B” is in the newregion “C.” These two regions may be two cross-sections. Then the“shaded” region for layer “X” is a region that is the union of “X,” allof the regions corresponding to layers further from the substrate as “X”and on the same side of and including “X.”

With reference now to FIG. 9, an illustration of layers for a preformdesign is depicted in accordance with an illustrative embodiment. Asdepicted, part manager 116 in FIG. 1 creates layers 900 for a preformfrom shaded cross-sections 800 in FIG. 8. Layers 900 include in-planeexcesses. In-plane excesses are the material excesses that extend in thedirection of the plane of the layers.

In the illustrative example, cross-sections are a set of curves. The setof curves are initially produced by intersecting a plane with the solid,and subsequent curve sets are generated by geometric operations. Thethree-dimensional cross-sections are the cross-sections havingseparation in the direction perpendicular to the substrate.

The two-dimensional cross-sections are formed by the projection of thethree-dimensional cross sections onto the substrate plane and thesubsequent in-plane curve sets generated by geometric operations. Thesegeometric operations may be, for example, union and offset. With thetwo-dimensional cross-sections, all of the curves from thesecross-sections are in a single plane and can be identified using twocoordinates.

In the illustrative examples, layers are the solid layers in theresultant geometry. For example, the layers in the depicted example arenon-substrate layers that are formed by the additive manufacturing tool.

Next, in FIG. 10, an illustration of layers for a preform on a partdesign is depicted in accordance with an illustrative embodiment. Inthis illustrative example, layers 900 for a preform are shown on partdesign 400 through an inverse of the transformation shown from FIG. 7 toFIG. 9.

Turning to FIG. 11, an illustration of a three-dimensional geometry isdepicted in accordance with an illustrative embodiment. In thisillustrative example, three-dimensional geometry 1100 is displayed ingraphical user interface 300. Three-dimensional geometry 1100 is createdusing layers 900 and part design 400 in FIG. 10.

With reference now to FIG. 12, an illustration of a preform design isdepicted in accordance with an illustrative embodiment. In thisillustrative example, part manager 116 in FIG. 1 creates preform design1200 using three-dimensional geometry 1100 in FIG. 11. As depicted,preform design 1200 includes preform 1202 and substrate 1204.

Turning now to FIG. 13, an illustration of output for evaluating apreform design is depicted in accordance with an illustrativeembodiment. In this illustrative example, output 1300 is an example ofevaluation information 214 in FIG. 2. In this illustrative example,output 1300 is a volumetric analysis of preform design 1200. Asdepicted, output 1300 includes part weight 1302, preform weight 1304,substrate weight 1306, additive weight 1308, plate dimensions 1310, andbuy to fly 1312.

In this illustrative example, part weight 1302 is the weight of the partcorresponding to part design 400 after machining a preform manufacturedusing preform design 1200 in FIG. 12. Preform weight 1304 is the weightof a preform manufactured using preform design 1200. Substrate weight1306 is the weight of the substrate on which layers are formed. Additiveweight 1308 is the weight of the layers formed on the substrate.

In this illustrative example, plate dimensions 1310 are the dimensionsof the substrate. Buy to fly 1312 is a metric used to define how muchraw material is wasted when machining is performed on a preform to forma part. For example, if 100 pounds of titanium are used to produce apart that weighs 5 pounds, buy to fly 1312 is equal to 20.

The illustration of the graphical user interface in FIGS. 3-13 is notmeant to imply limitations in the manner in which other illustrativeembodiments may be implemented. For example, additional parameters 304in FIG. 3 may change depending on the type of additive manufacturingsystem used. As depicted, additional parameters 304 are parameters foradditive manufacturing that utilizes a wire based electron-beam additivemanufacturing system. A powder based additive manufacturing system mayuse other types of parameters in addition to or in place of the onesillustrated in additional parameters 304.

As another example, cross-sections 600 in FIG. 6 are shown only in onedirection from substrate 500. Depending on the selection of a facet, thesections may extend in two directions that are opposite to each otherand perpendicular to substrate 500.

Turning next to FIG. 14, an illustration of a flowchart of a process formanaging a part is depicted in accordance with an illustrativeembodiment. The process illustrated in FIG. 14 may be implemented inpart environment 100 in FIG. 1. The different operations may beimplemented in part manager 116 to manage the manufacturing of preform110 and part 108 from preform 110 in FIG. 1.

The process begins by identifying parameters for a part (operation1400). These parameters may be obtained from a part design for the part.For example, the parameters may be located in a computer-aided designfile. In other illustrative examples, these parameters may be located ina file, such as a spreadsheet or some other data structure.

The process then identifies a number of additional parameters used inmanufacturing the part from a preform (operation 1402). These parametersare used with the parameters for the part to generate a preform design.

The process automatically generates a preform design for the preformusing the parameters for the part and the number of additionalparameters (operation 1404). The preform design enables manufacturingthe preform using an additive manufacturing system in a manufacturingenvironment.

Next, a determination is made as to whether the preform design meets anumber of goals (operation 1406). In determining whether the preformdesign meets a number of goals, the preform design may be evaluatedusing output that is related to the preform design. For example, theoutput may be a visualization preform design on a display system,valuation information generated for the preform design, or some othersuitable information.

If the preform design meets the number of goals, the process terminates.Otherwise, the process returns to operation 1402 to identify a number ofadditional parameters. When the number of additional parameters isidentified again, the number of additional parameters identified may bedifferent values from the values used previously for the number ofadditional parameters. In another illustrative example, the number ofadditional parameters may need to use other types of parameters. Eitherthe values, the type of parameters, or some combination of these two maybe used to identify the number of additional parameters.

Turning next to FIG. 15, an illustration of a flowchart of a process formanaging the manufacturing of a part from a preform is depicted inaccordance with an illustrative embodiment. The process begins byapplying a policy on manufacturing parts to a preform design for apreform (operation 1500). The policy may be one or more rules regardingthe manufacturing parts. This policy may include a number of rulesrelating to weight, cost, tolerances, or other suitable factors that maybe used in determining whether a preform is suitable for use inmanufacturing a part.

A determination is made as to whether to use an additive manufacturingprocess to manufacture the preform based on the application of thepolicy to the design for the preform (operation 1502). The processterminates thereafter.

Turning now to FIG. 16, an illustration of a flowchart of a process forcreating a preform design is depicted in accordance with an illustrativeembodiment. The process illustrated in FIG. 16 may be implemented inpart manager 116 in part environment 100 in FIG. 1. The differentoperations illustrated in FIG. 3 correspond to the visualizations ofoperations performed in FIGS. 3-13.

The process begins by identifying additional parameters formanufacturing a part from a preform (operation 1600). The additionalparameters in operation 1600 are additional parameters 124 in FIG. 1.The additional parameters describe information such as offsets,excesses, or some combination thereof that are needed to machine thepreform to form the part; the location and thicknesses of the substrate;material density; and other suitable information that may be needed togenerate the preform design that can be processed to form a part.

The process then identifies a facet for a substrate location (operation1602). In this illustrative example, a facet is a face or side of thepreform design. The selection sets the build direction. The builddirection is the direction in which layers are formed on a substrate tomanufacture the preform.

For example, the facet may be selected such that the layers are formedin one direction from the substrate rather than in two directions. Thisselection may reduce the cost of manufacturing the preform. In theillustrative example, the facet may be identified by user input orthrough an analysis to identify optimal facet manufacturing a preform tomeet desired goals.

The process then identifies a location for the substrate with respect tothe part design (operation 1604). In this operation, cross-sections ofthe three-dimensional geometry for the part design are calculated suchthat they are parallel to the selected facet. These cross-sections arecalculated starting in the plane of the facet and then moving in stepsin both directions from the plane in which the facet lies. The size ofthe step may be set by a substrate optimality resolution parameter. Theparameter defines a step size for optimal substrate location.

In this operation, cross-sections of the three-dimensional geometry forthe part design are calculated such that they are parallel to theselected facet. These cross-sections are calculated starting in theplane of the facet and steps in both directions from the plane in whichthe facet lies. The steps are those set by the substrate optimalityresolution parameter.

The larger area of the two outer cross-sections is used to determinewhether the next cross section should be in the up or down direction.This process is repeated until the desired substrate thickness has beenreached. In this illustrative example, the substrate thickness includesexcesses.

The process then identifies cross-sections in the three-dimensional partdesign (operation 1606). In this illustrative example, cross-sections ofthe three-dimensional geometry of the part design are calculated in bothdirections from the plane of the facet. These cross-sections arecalculated using the layer thickness as an offset for each subsequentcross-section until the cross-section is empty. As depicted, the offsetis a distance from the substrate.

The process then translates the cross-sections in the three-dimensionalgeometry of the part design into a two-dimensional form (operation1608). In operation 1608, all of the cross-sections are projected ontothe substrate, creating cross-sections with two-dimensional geometries.For example, the three-dimensional cross-sections in FIGS. 5, 6, and 10have separation in the direction perpendicular to the substrate.

The two-dimensional cross-sections in FIGS. 7, 8, and 9 are all in acommon plane and could be described using two coordinates. Additionally,the process may also attempt to clean any inconsistencies resulting frompoor three-dimensional geometry or degenerate cross-section situations.

The additive manufacturing systems receive instructions, such asprograms or commands, to manufacture the preform. Due to a variety ofsoftware options, geometry specifications, file types, andcomputer-aided design (CAD) operator behaviors, the geometry in thegeometry kernel might have inconsistencies due to inconsistencies in thegeometry or in the ability of the geometric kernel to make process ofthe file.

As a result, inconsistencies, such as a hole or other connectivityerror, may be present in the surface of the part. The hole might lead toa cross-section that does not consist of a number of closed curves. As aresult, “cleaning” may be performed in an attempt to close these gaps.In these illustrative examples, the inconsistencies may include gaps,zero length curves, or other inconsistencies that may be present.

The process then creates shaded cross-sections (operation 1610). Theshaded cross-sections are created using Boolean unions on thetwo-dimensional geometries created in operation 1608. These Booleanunions “shade” the layers farther from the substrate onto those belowthem. The result will be that, on either side, any cross-section willcontain every cross-section that is farther than itself from thesubstrate.

The process then identifies offset regions for material excesses(operation 1612). In operation of 1612, the boundaries of the shadedcross-sections are adjusted by offsetting the shaded cross-sections fromoperation 1610 and taking into account in-plane material excesses. Forexample, interior openings may take into account such that the openingsdo not disappear during formation of the preform.

This adjustment results in two-dimensional cross-sections. These offsetregions are regions in which excess material is present such that thepreform may be machined to form the part. These regions of excessmaterial also may be regions that are used by tooling in the additivemanufacturing system, the machining system, or some combination thereof.

In the list of examples, the cross-sections are considered regions inwhich groups of points are defined by interior and exterior boundaries.For example, the offset “B” of region “A” by “X” would be the set all ofpoints “p” such that there exists some point in region “A” whosedistance from “p” is less than or equal to “X”.

Next, the process translates two-dimensional layers intothree-dimensional layers (operation 1614). In this operation, theprocess applies an inverse of the transformation from operation 1608 tothe boundary in operation 1612 and offsets additionally for each layer'sdistance from the substrate and excess in the build direction.

The process then creates a three-dimensional layer geometry (operation1616). In operation 1616, the process creates a cross section of thepreform design by stitching together two copies of the curve or curvesin operation 1614, offset by the layer thickness, and “capping” theresult. For example, if a circle is present, this operation would startby creating a tube, and the “capping” would result in a closed cylinder.

The process then generates the substrate extents and the substrategeometry to form a preform design (operation 1618). In operation 1618,the process applies shading to the cross sections of the substrate fromboth the top and bottom layers. In this operation, the process alsogenerates a rectangular bounding box around the layer that has as littledistance as possible between the edges of the bounding box and theboundary of the layer.

In other words, the bounding box is positioned and sized to have assmall of an area as possible while keeping the substrate within thebounding box. In operation 1618, the process generates the rectangularsolid for the substrate using this rectangular bounding box and thelocations determined in operation 1604.

The process then generates a volumetric analysis (operation 1620) withthe process terminating thereafter. The biometric analysis is an exampleof output 212 shown in block form in FIG. 2. In operation 1620, theprocess aggregates the volumes of the layers in operation 1616 tocalculate volume and weight of deposited material. In this operation,the process also calculates the volume of the preform and the weight ofthe substrate from dimensions in the material density.

With the volumetric analysis, a determination may be made as to whetherthe preform design meets goals in manufacturing a preform that can bemachined to form the part. For example, the results of the volumetricanalysis may be used for cost analysis or other suitable analysis.

If the result is not desirable, the process in FIG. 16 may be repeatedusing different additional parameters. For example, a different type ofmaterial may be used with the material density that may have differentadditive layer thicknesses or material offsets.

The flowcharts and block diagrams in the different depicted embodimentsillustrate the architecture, functionality, and operation of somepossible implementations of apparatuses and methods in an illustrativeembodiment. In this regard, each block in the flowcharts or blockdiagrams may represent at least one of a module, a segment, a function,or a portion of an operation or step. For example, one or more of theblocks may be implemented as program code, hardware, or a combination ofthe program code and hardware.

When implemented in hardware, the hardware may, for example, take theform of integrated circuits that are manufactured or configured toperform one or more operations in the flowcharts or block diagrams. Whenimplemented as a combination of program code and hardware, theimplementation may take the form of firmware. Each block in theflowcharts or the block diagrams may be implemented using specialpurpose hardware systems that perform the different operations orcombinations of special purpose hardware and program code run by thespecial purpose hardware.

In some alternative implementations of an illustrative embodiment, thefunction or functions noted in the blocks may occur out of the ordernoted in the figures. For example, in some cases, two blocks shown insuccession may be performed substantially concurrently, or the blocksmay sometimes be performed in the reverse order, depending upon thefunctionality involved. Also, other blocks may be added in addition tothe illustrated blocks in a flowchart or block diagram.

For example, operation 1402 may be performed prior to operation 1400 inFIG. 14. In another illustrative example, operation 1620 in FIG. 16 maybe omitted. In yet another illustrative example, the parameters inoperation 1600 may be identified from a configuration file withoutrequiring user input to a graphical user interface.

Turning now to FIG. 17, an illustration of a block diagram of a dataprocessing system is depicted in accordance with an illustrativeembodiment. Data processing system 1700 may be used to implementcomputer system 118 in FIG. 1 and FIG. 2. In this illustrative example,data processing system 1700 includes communications framework 1702,which provides communications between processor unit 1704, memory 1706,persistent storage 1708, communications unit 1710, input/output (I/O)unit 1712, and display 1714. In this example, communications framework1702 may take the form of a bus system.

Processor unit 1704 serves to execute instructions for software that maybe loaded into memory 1706. Processor unit 1704 may be a number ofprocessors, a multi-processor core, or some other type of processor,depending on the particular implementation.

Memory 1706 and persistent storage 1708 are examples of storage devices1716. A storage device is any piece of hardware that is capable ofstoring information, such as, for example, without limitation, at leastone of data, program code in functional form, or other suitableinformation either on a temporary basis, a permanent basis, or both on atemporary basis and a permanent basis. Storage devices 1716 may also bereferred to as computer readable storage devices in these illustrativeexamples. Memory 1706, in these examples, may be, for example, a randomaccess memory or any other suitable volatile or non-volatile storagedevice. Persistent storage 1708 may take various forms, depending on theparticular implementation.

For example, persistent storage 1708 may contain one or more componentsor devices. For example, persistent storage 1708 may be a hard drive, asolid state hard drive, a flash memory, a rewritable optical disk, arewritable magnetic tape, or some combination of the above. The mediaused by persistent storage 1708 also may be removable. For example, aremovable hard drive may be used for persistent storage 1708.

Communications unit 1710, in these illustrative examples, provides forcommunications with other data processing systems or devices. In theseillustrative examples, communications unit 1710 is a network interfacecard.

Input/output unit 1712 allows for input and output of data with otherdevices that may be connected to data processing system 1700. Forexample, input/output unit 1712 may provide a connection for user inputthrough at least one of a keyboard, a mouse, or some other suitableinput device. Further, input/output unit 1712 may send output to aprinter. Display 1714 provides a mechanism to display information to auser.

Instructions for at least one of the operating system, applications, orprograms may be located in storage devices 1716, which are incommunication with processor unit 1704 through communications framework1702. The processes of the different embodiments may be performed byprocessor unit 1704 using computer-implemented instructions, which maybe located in a memory, such as memory 1706.

These instructions are referred to as program code, computer usableprogram code, or computer readable program code that may be read andexecuted by a processor in processor unit 1704. The program code in thedifferent embodiments may be embodied on different physical or computerreadable storage media, such as memory 1706 or persistent storage 1708.

Program code 1718 is located in a functional form on computer readablemedia 1720 that is selectively removable and may be loaded onto ortransferred to data processing system 1700 for execution by processorunit 1704. Program code 1718 and computer readable media 1720 formcomputer program product 1722 in these illustrative examples. In oneexample, computer readable media 1720 may be computer readable storagemedia 1724 or computer readable signal media 1726.

In these illustrative examples, computer readable storage media 1724 isa physical or tangible storage device used to store program code 1718rather than a medium that propagates or transmits program code 1718.Alternatively, program code 1718 may be transferred to data processingsystem 1700 using computer readable signal media 1726. Computer readablesignal media 1726 may be, for example, a propagated data signalcontaining program code 1718. For example, computer readable signalmedia 1726 may be at least one of an electromagnetic signal, an opticalsignal, or any other suitable type of signal. These signals may betransmitted over at least one of communications links, such as wirelesscommunications links, optical fiber cable, coaxial cable, a wire, or anyother suitable type of communications link.

The different components illustrated for data processing system 1700 arenot meant to provide architectural limitations to the manner in whichdifferent embodiments may be implemented. The different illustrativeembodiments may be implemented in a data processing system includingcomponents in addition to or in place of those illustrated for dataprocessing system 1700. Other components shown in FIG. 17 can be variedfrom the illustrative examples shown. The different embodiments may beimplemented using any hardware device or system capable of runningprogram code 1718.

Illustrative embodiments of the disclosure may be described in thecontext of aircraft manufacturing and service method 1800 as shown inFIG. 18 and aircraft 1900 as shown in FIG. 19. Turning first to FIG. 18,an illustration of a block diagram of an aircraft manufacturing andservice method is depicted in accordance with an illustrativeembodiment. During pre-production, aircraft manufacturing and servicemethod 1800 may include specification and design 1802 of aircraft 1900in FIG. 19 and material procurement 1804.

During production, component and subassembly manufacturing 1806 andsystem integration 1808 of aircraft 1900 in FIG. 19 take place.Thereafter, aircraft 1900 may go through certification and delivery 1810in order to be placed in service 1812. While in service 1812 by acustomer, aircraft 1900 is scheduled for routine maintenance and service1814, which may include modification, reconfiguration, refurbishment,and other maintenance or service.

Each of the processes of aircraft manufacturing and service method 1800may be performed or carried out by a system integrator, a third party,an operator, or some combination thereof. In these examples, theoperator may be a customer. For the purposes of this description, asystem integrator may include, without limitation, any number ofaircraft manufacturers and major-system subcontractors; a third partymay include, without limitation, any number of vendors, subcontractors,and suppliers; and an operator may be an airline, a leasing company, amilitary entity, a service organization, and so on.

With reference now to FIG. 19, an illustration of a block diagram of anaircraft is depicted in which an illustrative embodiment may beimplemented. In this example, aircraft 1900 is produced by aircraftmanufacturing and service method 1800 in FIG. 18 and may includeairframe 1902 with a plurality of systems 1904 and interior 1906.

Examples of systems 1904 include one or more of propulsion system 1908,electrical system 1910, hydraulic system 1912, and environmental system1914. Any number of other systems may be included. Although an aerospaceexample is shown, different illustrative embodiments may be applied toother industries, such as the automotive industry. Apparatuses andmethods embodied herein may be employed during at least one of thestages of aircraft manufacturing and service method 1800 in FIG. 18.

In one illustrative example, components or subassemblies produced incomponent and subassembly manufacturing 1806 in FIG. 18 may befabricated or manufactured in a manner similar to components orsubassemblies produced while aircraft 1900 is in service 1812 in FIG.18. As yet another example, one or more apparatus embodiments, methodembodiments, or a combination thereof may be utilized during productionstages, such as component and subassembly manufacturing 1806 and systemintegration 1808 in FIG. 18.

One or more apparatus embodiments, method embodiments, or a combinationthereof may be utilized while aircraft 1900 is in service 1812, duringmaintenance and service 1814 in FIG. 18, or both. The use of a number ofthe different illustrative embodiments may substantially expedite theassembly of aircraft 1900, reduce the cost of aircraft 1900, or bothexpedite the assembly of aircraft 1900 and reduce the cost of aircraft1900.

For example, one or more illustrative examples may be used tomanufacture parts in the different stages. Further, one or moreillustrative examples also may be used to determine the feasibility ofusing preforms for use in manufacturing parts.

Turning now to FIG. 20, an illustration of a block diagram of a productmanagement system is depicted in accordance with an illustrativeembodiment. Product management system 2000 is a physical hardwaresystem. In this illustrative example, product management system 2000 mayinclude at least one of manufacturing system 2002 or maintenance system2004.

Manufacturing system 2002 is configured to manufacture products, such asaircraft 1900 in FIG. 19. As depicted, manufacturing system 2002includes manufacturing equipment 2006. Manufacturing equipment 2006includes at least one of fabrication equipment 2008 or assemblyequipment 2010.

Fabrication equipment 2008 is equipment that may be used to fabricatecomponents for parts used to form aircraft 1900. For example,fabrication equipment 2008 may include machines and tools. Thesemachines and tools may be at least one of a drill, a hydraulic press, afurnace, a mold, a composite tape laying machine, a vacuum system, alathe, or other suitable types of equipment. Fabrication equipment 2008may be used to fabricate at least one of metal parts, composite parts,semiconductors, circuits, fasteners, ribs, skin panels, spars, antennas,or other suitable types of parts.

Assembly equipment 2010 is equipment used to assemble parts to formaircraft 1900. In particular, assembly equipment 2010 may be used toassemble components and parts to form aircraft 1900. Assembly equipment2010 also may include machines and tools.

These machines and tools may be at least one of a robotic arm, acrawler, a faster installation system, a rail-based drilling system, ora robot. Assembly equipment 2010 may be used to assemble parts such asseats, horizontal stabilizers, wings, engines, engine housings, landinggear systems, and other parts for aircraft 1900.

In this illustrative example, maintenance system 2004 includesmaintenance equipment 2012. Maintenance equipment 2012 may include anyequipment needed to perform maintenance on aircraft 1900. Maintenanceequipment 2012 may include tools for performing different operations onparts on aircraft 1900. These operations may include at least one ofdisassembling parts, refurbishing parts, inspecting parts, reworkingparts, manufacturing replacement parts, or other operations forperforming maintenance on aircraft 1900. These operations may be forroutine maintenance, inspections, upgrades, refurbishment, or othertypes of maintenance operations.

In the illustrative example, maintenance equipment 2012 may includeultrasonic inspection devices, x-ray imaging systems, vision systems,drills, crawlers, and other suitable device. In some cases, maintenanceequipment 2012 may include fabrication equipment 2008, assemblyequipment 2010, or both to produce and assemble parts that may be neededfor maintenance. In the illustrative example, part manufacturing system102 in FIG. 1 may be implemented within at least one of manufacturingsystem 2002 or maintenance system 2004.

Product management system 2000 also includes control system 2014.Control system 2014 is a hardware system and may also include softwareor other types of components. Control system 2014 is configured tocontrol the operation of at least one of manufacturing system 2002 ormaintenance system 2004.

In particular, control system 2014 may control the operation of at leastone of fabrication equipment 2008, assembly equipment 2010, ormaintenance equipment 2012. In the illustrative example, part manager116 in FIG. 1 may be implemented as part of control system 2014 or maybe in communication with control system 2014.

The hardware in control system 2014 may be using hardware that mayinclude computers, circuits, networks, and other types of equipment. Thecontrol may take the form of direct control of manufacturing equipment2006. For example, robots, computer-controlled machines, and otherequipment may be controlled by control system 2014.

In other illustrative examples, control system 2014 may manageoperations performed by human operators 2016 in manufacturing orperforming maintenance on aircraft 1900 in FIG. 19. For example, controlsystem 2014 may assign tasks, provide instructions, display models, orperform other operations to manage operations performed by humanoperators 2016. In these illustrative examples, part manager 116 in FIG.1 and FIG. 2 may be implemented in control system 2014 to manage atleast one of the manufacturing or maintenance of aircraft 1900 in FIG.19.

In the different illustrative examples, human operators 2016 may operateor interact with at least one of manufacturing equipment 2006,maintenance equipment 2012, or control system 2014. This interaction maybe performed to manufacture aircraft 1900.

Of course, product management system 2000 may be configured to manageother products other than aircraft 1900. Although aircraft managementsystem 2000 has been described with respect to manufacturing in theaerospace industry, aircraft management system 2000 may be configured tomanage products for other industries. For example, aircraft managementsystem 2000 may be configured to manufacture products for the automotiveindustry as well as any other suitable industries.

Thus, the illustrative embodiments provide a method and apparatus formanaging the manufacturing preforms and parts from preforms. Asdescribed above, one or more of the illustrative examples provide amethod and apparatus that overcome a technical problem with the time andeffort needed to create a preform design.

In the illustrative examples, a part manager automatically generates apreform design from parameters for a part design and a number ofadditional parameters used in manufacturing the preform. The partmanager allows for changes to the preform design to be performed morequickly than with currently used techniques.

Further, the part manager generates the preform design without needingthe human operator to modify the part design displayed on a graphicaluser interface. By eliminating the need for this operation, the preformdesign may be generated more quickly and accurately as compared tocurrently used techniques.

The output generated by the part manager may be used to evaluate thepreform design. For example, the output may include at least one of avisualization of the preform design or evaluation information. Thisinformation may be used by at least one of the part manager, the humanoperator, or some other entity in determining whether a changed preformdesign is needed. Further, the output may be used to determine whetherthe parts are suitable for manufacturing through the use of a preformcreated by an additive manufacturing system, such as a wire basedadditive manufacturing system.

The description of the different illustrative embodiments has beenpresented for purposes of illustration and description and is notintended to be exhaustive or limited to the embodiments in the formdisclosed. The different illustrative examples describe components thatperform actions or operations.

In an illustrative embodiment, a component may be configured to performthe action or operation described. For example, the component may have aconfiguration or design for a structure that provides the component anability to perform the action or operation that is described in theillustrative examples as being performed by the component.

Many modifications and variations will be apparent to those of ordinaryskill in the art. Further, different illustrative embodiments mayprovide different features as compared to other desirable embodiments.The embodiment or embodiments selected are chosen and described in orderto best explain the principles of the embodiments, the practicalapplication, and to enable others of ordinary skill in the art tounderstand the disclosure for various embodiments with variousmodifications as are suited to the particular use contemplated.

What is claimed is:
 1. An apparatus comprising: a part manager thatidentifies parameters for a part; identifies a number of additionalparameters used in manufacturing the part from a preform; andautomatically generates a preform design for the preform using theparameters for the part and the number of additional parameters, whereinthe preform design enables manufacturing the preform using an additivemanufacturing system.
 2. The apparatus of claim 1, wherein the partmanager repeats identifying the number of additional parameters formanufacturing the part from the preform; and automatically generatingthe preform design for the preform using the parameters for the part andthe number of additional parameters for manufacturing the part from thepreform until the preform design meets a number of goals.
 3. Theapparatus of claim 1, wherein the part manager displays the preform on adisplay system using the preform design, wherein the part managerrepeats identifying, by a computer system, the number of additionalparameters used in manufacturing the part from the preform; andautomatically generating, by the computer system, the preform design forthe preform using the parameters for the part and the number ofadditional parameters using changes to the number of additionalparameters.
 4. The apparatus of claim 1, wherein the part managerapplies a policy on manufacturing parts to the preform design anddetermines whether to use the additive manufacturing system tomanufacture the preform based on an application of the policy to thepreform design.
 5. The apparatus of claim 1, wherein the part manageridentifies a weight for the preform and a cost estimate for the preformusing the weight.
 6. The apparatus of claim 1, wherein the part managermanufactures the preform using the preform design.
 7. The apparatus ofclaim 6, wherein, in manufacturing the preform using the preform design,the part manager generates instructions for the additive manufacturingsystem using the preform design and the number of additional parameters,wherein the instructions are used by the additive manufacturing systemto form the preform for the part.
 8. The apparatus of claim 7, whereinthe part manager machines the preform to form the part.
 9. The apparatusof claim 1, wherein the number of additional parameters is selected fromat least one of a build direction, a substrate location, a substratethickness, an additive material offset, a plate excess, a substrateexcess, a material density, an additive layer thickness, or a platethickness.
 10. The apparatus of claim 7, wherein the instructions areselected from at least one of commands, program code, source code, ormachine code.
 11. The apparatus of claim 1, wherein the additivemanufacturing system is selected from at least one of an electron beamadditive manufacturing system, a powder based electron beam additivemanufacturing system, a wire based electron beam additive manufacturingsystem, a laser additive manufacturing system, a selective heatsintering system, a laser sintering system, or a fusion depositionmodeling system.
 12. A method for managing a part, the methodcomprising: identifying, by a computer system, parameters for the part;identifying, by the computer system, a number of additional parametersused in manufacturing the part from a preform; and automaticallygenerating, by the computer system, a preform design for the preformusing the parameters for the part and the number of additionalparameters, wherein the preform design enables manufacturing the preformusing an additive manufacturing system in a manufacturing environment.13. The method of claim 12 further comprising: repeating identifying, bythe computer system, the number of additional parameters formanufacturing the part from the preform; and automatically generating,by the computer system, the preform design for the preform using theparameters for the part and the number of additional parameters formanufacturing the part from the preform until the preform design meets anumber of goals.
 14. The method of claim 12 further comprising:displaying the preform on a display system using the preform design, andfurther comprising: repeating identifying, by the computer system, thenumber of additional parameters used in manufacturing the part from thepreform and automatically generating, by the computer system, thepreform design for the preform using the parameters for the part and thenumber of additional parameters, using changes to the number ofadditional parameters.
 15. The method of claim 12 further comprising:applying a policy on manufacturing parts to the preform design; anddetermining whether to use the additive manufacturing system tomanufacture the preform based on an application of the policy to thepreform design.
 16. The method of claim 12 further comprising:identifying a weight for the preform; and identifying a cost estimatefor the preform using the weight.
 17. The method of claim 12 furthercomprising: manufacturing the preform using the preform design.
 18. Themethod of claim 17, wherein manufacturing the preform using the preformdesign comprises: generating, by the computer system, instructions forthe additive manufacturing system using the preform design and thenumber of additional parameters, wherein the instructions are used bythe additive manufacturing system to form the preform for the part; andmanufacturing the preform using the instructions and the additivemanufacturing system.
 19. The method of claim 18 further comprising:machining the preform to form the part.
 20. The method of claim 12,wherein the number of additional parameters is selected from at leastone of a build direction, a substrate location, a substrate thickness,an additive material offset, a plate excess, a substrate excess, amaterial density, an additive layer thickness, or a plate thickness. 21.The method of claim 18, wherein the instructions are selected from atleast one of commands, program code, source code, or machine code. 22.The method of claim 12, wherein the additive manufacturing system isselected from at least one of an electron beam additive manufacturingsystem, a powder based electron beam additive manufacturing system, awire based electron beam additive manufacturing system, a laser additivemanufacturing system, a selective heat sintering system, a lasersintering system, or a fusion deposition modeling system.
 23. A preformmanagement system comprising: a part manager that identifies parametersfor a part; identifies a number of additional parameters formanufacturing the part from a preform; generates a preform design forthe preform; displays the preform design on a display system; andoutputs feasibility information about the preform, wherein the preformdesign enables manufacturing the preform using an additive manufacturingsystem.
 24. The preform management system of claim 23, wherein thefeasibility information is selected from at least one of a weight or anamount of material needed to form the preform.
 25. The preformmanagement system of claim 23, wherein the part manager controlsmanufacturing of the preform using the preform design.
 26. The preformmanagement system of claim 25, wherein in controlling manufacturing ofthe preform using the preform design, the part manager generatesinstructions for the additive manufacturing system using the preformdesign and the number of additional parameters and sends theinstructions for the additive manufacturing system, wherein theinstructions are used by the additive manufacturing system to form thepreform for the part and controls manufacturing of the preform using theinstructions and the additive manufacturing system.